WO2019094294A1 - Appareil et procédé de fabrication additive - Google Patents
Appareil et procédé de fabrication additive Download PDFInfo
- Publication number
- WO2019094294A1 WO2019094294A1 PCT/US2018/058927 US2018058927W WO2019094294A1 WO 2019094294 A1 WO2019094294 A1 WO 2019094294A1 US 2018058927 W US2018058927 W US 2018058927W WO 2019094294 A1 WO2019094294 A1 WO 2019094294A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- build
- powder
- collector
- additive manufacturing
- build platform
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims abstract description 35
- 239000000654 additive Substances 0.000 title claims abstract description 29
- 230000000996 additive effect Effects 0.000 title claims abstract description 29
- 239000000843 powder Substances 0.000 claims description 96
- 230000007246 mechanism Effects 0.000 claims description 31
- 239000000463 material Substances 0.000 claims description 17
- 238000000151 deposition Methods 0.000 claims description 7
- 238000002844 melting Methods 0.000 description 15
- 230000008018 melting Effects 0.000 description 15
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 238000000149 argon plasma sintering Methods 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 230000008021 deposition Effects 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 238000012805 post-processing Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 3
- 238000000110 selective laser sintering Methods 0.000 description 3
- 229910000601 superalloy Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000011960 computer-aided design Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010894 electron beam technology Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910001011 CMSX-4 Inorganic materials 0.000 description 1
- 229910000684 Cobalt-chrome Inorganic materials 0.000 description 1
- -1 Rene N4 Inorganic materials 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 239000008186 active pharmaceutical agent Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000010952 cobalt-chrome Substances 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 229920006351 engineering plastic Polymers 0.000 description 1
- 238000010100 freeform fabrication Methods 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000005495 investment casting Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910001173 rene N5 Inorganic materials 0.000 description 1
- 238000007528 sand casting Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000006276 transfer reaction Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/22—Driving means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/30—Platforms or substrates
- B22F12/37—Rotatable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F5/106—Tube or ring forms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/70—Recycling
- B22F10/73—Recycling of powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/70—Gas flow means
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure generally relates to methods and systems adapted to perform additive manufacturing (“AM”) processes, for example by direct melt laser manufacturing (“DMLM”), on a larger scale format.
- AM additive manufacturing
- DMLM direct melt laser manufacturing
- AM additive manufacturing
- NPS net or near net shape
- AM encompasses various manufacturing and prototyping techniques known under a variety of names, including freeform fabrication, 3D printing, rapid prototyping/tooling, etc.
- AM techniques are capable of fabricating complex components from a wide variety of materials.
- a freestanding object can be fabricated from a computer aided design (CAD) model.
- CAD computer aided design
- a particular type of AM process uses an irradiation emission directing device that directs an energy beam, for example, an electron beam or a laser beam, to sinter or melt a powder material, creating a solid three-dimensional object in which particles of the powder material are bonded together.
- an energy beam for example, an electron beam or a laser beam
- Different material systems for example, engineering plastics, thermoplastic elastomers, metals, and ceramics are in use.
- Laser sintering or melting is a notable AM process for rapid fabrication of functional prototypes and tools.
- Applications include direct manufacturing of complex workpieces, patterns for investment casting, metal molds for injection molding and die casting, and molds and cores for sand casting. Fabrication of prototype objects to enhance communication and testing of concepts during the design cycle are other common usages of AM processes.
- Selective laser sintering, direct laser sintering, selective laser melting, and direct laser melting are common industry terms used to refer to producing three- dimensional (3D) objects by using a laser beam to sinter or melt a fine powder. More accurately, sintering entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material, whereas melting entails fully melting particles of a powder to form a solid homogeneous mass.
- the physical processes associated with laser sintering or laser melting include heat transfer to a powder material and then either sintering or melting the powder material.
- DMLS direct metal laser sintering
- DMLM direct metal laser melting
- Post processing procedures include removal of excess powder by, for example, blowing or vacuuming. Other post processing procedures include a stress release process. Additionally, thermal and chemical post processing procedures can be used to finish the part.
- the walls of the powder bed define the amount of powder needed to make a part.
- the size of object to be built is limited by the size of the machine's powder bed.
- Increasing the size of the powder bed has limits due to the needed large angle of incidence that can lower scan quality, and weight of the powder bed which can exceed the capabilities of steppers used to lower the build platform.
- Additive manufacturing apparatus is generally provided, along with methods of forming an object therewith.
- the additive is generally provided, along with methods of forming an object therewith.
- the additive is generally provided, along with methods of forming an object therewith.
- manufacturing apparatus includes at least one build unit; a build platform (e.g., a rotating build platform); and a pair of collectors positioned on the apparatus such that a first collector contacts an outer surface of an object as it is formed on the build platform and a second collector contacts an inner surface of the object as it is formed on the build platform.
- a build platform e.g., a rotating build platform
- collectors positioned on the apparatus such that a first collector contacts an outer surface of an object as it is formed on the build platform and a second collector contacts an inner surface of the object as it is formed on the build platform.
- the method of manufacturing an object may include: (a) depositing powder onto a build platform from at least one build unit; (b) bonding at least one selected portion of the powder to form an object having an outer surface and an inner surface; (c) positioning an outer collector on the outer surface of the object and positioning an inner collector on the inner surface of the object; and (d) repeating at least steps (a) through (c) to form the object on the build platform.
- the method may include rotating the build platform during at least part of the build (e.g., during at least steps (a) through (c)).
- FIG. 1 is a top view showing an additive manufacturing print strategy in accordance with an embodiment of the invention
- FIG. 2 is a schematic diagram showing a front view showing a cross section of an additive manufacturing apparatus according an embodiment of the invention
- FIG. 3 is a perspective view of an additive manufacturing apparatus in accordance with an embodiment of the invention.
- FIG. 4 is an expanded cross section of a build unit and part of the rotating build platform of the additive manufacturing apparatus of FIG. 3;
- FIG. 5 shows an exemplary cross-sectional view of a build unit during an object build between a pair of collectors over a build platform.
- methods and apparatus can be used to perform powder-based additive layer manufacturing of a large object, particularly large, annular components (e.g., annular components of turbomachinery).
- powder-based additive layer manufacturing include but are not limited to selective laser sintering (SLS), selective laser melting (SLM), direct metal laser sintering (DMLS), direct metal laser melting (DMLM), binder jetting, and electron beam melting (EBM) processes.
- SLS selective laser sintering
- SLM selective laser melting
- DMLS direct metal laser sintering
- DMLM direct metal laser melting
- binder jetting binder jetting
- EBM electron beam melting
- an additive manufacturing apparatus includes a mobile build unit assembly, which is configured to include several components that are essential for additively manufacturing high-precision, large-scale objects.
- These build components include, for example, a powder recoating mechanism and a bonding mechanism (e.g., an irradiation beam directing mechanism, a binder jetting apparatus, etc.).
- the build unit is advantageously attached to a positioning mechanism that allows two- or three-dimensional movement (along x-, y- and z-axes) throughout the build environment, as well as rotation of the build unit in a way that allows leveling of the powder in any direction desired.
- the positioning mechanism may be a gantry, a delta robot, a cable robot, a robotic arm, a belt drive, or the like.
- one embodiment of the additive manufacturing apparatus also includes a rotating build platform.
- this build platform has a substantially circular configuration, but is not so limited. Since the build unit of the apparatus is mobile, this eliminates the need to lower the build platform as successive layers of powder are built up, as it is in conventional powder bed systems. Accordingly, the rotating platform of the present invention is preferably vertically stationary.
- FIG. 1 shows a top view of the apparatus 200 having a mobile build unit 202 and a rotating build platform 210.
- the rotational direction of the build platform 210 is shown with reference to the curved arrow "r".
- the build unit 202 which includes an irradiation beam directing mechanism (not shown), may be translated along the x-, y- or z-axis as indicated by the linear arrows.
- FIG. 1 shows a top view of the apparatus 200 having a mobile build unit 202 and a rotating build platform 210.
- the rotational direction of the build platform 210 is shown with reference to the curved arrow "r".
- the build unit 202 which includes an irradiation beam directing mechanism (not shown), may be translated along the x-, y- or z-axis as indicated by the linear arrows.
- FIG. 1 shows a top view of the apparatus 200 having a mobile build unit 202 and a rotating build platform 210.
- the rotational direction of the build platform 210 is
- FIG. 1 also shows a built object 230 that is formed on the build platform 210 between a pair of collectors 100 (e.g., an outer collector 224 and an inner collector 226 in the embodiment shown).
- a pair of collectors 100 e.g., an outer collector 224 and an inner collector 226 in the embodiment shown.
- the outer collector 224 contacts the outer surface 229 of the built object 230
- the inner collector 226 contacts the inner surface 231 of the built object 230.
- the collectors 224, 226 hold loose powder 314 against the outer surface 229 and inner surface 231 during a build process.
- the collectors 100 utilize their collector arms 110 to form a powder bed 314 of loose powder on the outside of the inner and outer surfaces 229, 231.
- the build envelopes and/or build walls are not required to build the object 230.
- the outer surface 229 and inner surface 231 are exposed below the area where the collectors 224, 226 make contact therewith, respectively.
- the loose powder 315 may be held at the top of the build object 230 during the solidifying the object 230.
- each collector 224, 226 includes a collection arm 110 contacting the outer surface 229, 231 to form a powder cavity 113 therebetween.
- a sealing member 112 may be on the end of each collection arm 110 such that the contact therebetween may hold the powder within the powder cavity 113 without allowing any substantial leakage therebetween.
- the outer collectors 224 and inner collectors 226 are pivotally attached to the build unit 302 (e.g., to the powder dispenser 512).
- support members 114 may connect the outer collectors 224 and inner collectors 226 to the build unit 302.
- the support members 114 may also include one or more pivot joint 116 configured to maintain contact between the outer collectors 224 and inner collectors 226 and the exterior surfaces 229, 231 of the object 230, respectively.
- the pivot joints 116 may allow for the collectors 224, 226 to be biased toward the object 230 such that sufficient contact is kept therebetween to inhibit leakage, even as the build unit 302 is moved about the apparatus.
- the pivot joint can be controlled with the movement of the build unit 302.
- support members 114 may be attached to the positioning mechanism 325 (e.g., the z-crossbeams 325Z or the x-crossbeams 325X).
- FIG. 2 further depicts a schematic representation of an additive
- the apparatus 300 may include a build enclosure 301 housing the entire apparatus 300 and object 230 to be built.
- the apparatus 300 includes a build unit 302 and a rotating build platform 310.
- the apparatus builds an object 230 in a powder bed 314 formed between the outer collector 224 and the inner collector 226.
- the object 230 is a large annular object, such as, but not limited to, a turbine or vane shrouding, a central engine shaft, a casing, a compressor liner, a combustor liner, a duct, etc.
- the build unit 302 may be configured to include several components for additively manufacturing a high-precision, large-scale object or multiple smaller objects.
- a mobile build unit may include, for example, a powder delivery mechanism, a powder recoating mechanism, a gas-flow mechanism with a gas-flow zone and an irradiation beam directing mechanism.
- FIG. 4 includes additional details of an exemplary mobile build unit to be used in accordance with particular embodiments of the present invention.
- the positioning mechanism 325 may be an X-Y-Z gantry has one or more x-crossbeams 325X (e.g., as shown in FIGS. 2 and 3) that independently move the build unit 302 along the x-axis (i.e., left or right), one or more y-crossbeams 325Y that respectively move the build unit 302 along the y-axis (i.e. inward or outward). Such two-dimensional movements across the x-y plane are substantially parallel to the build platform 210 or a build area therewithin. Additionally, the positioning mechanism 325 has one or more z-crossbeams 325Z (two shown in FIG. 2) that moves the build unit 302 along the z-axis (i.e. upward and downward or substantially perpendicular to the build platform 310 or a build area therewithin). The positioning mechanism 325 is further operable to rotate the build unit 302 around the c-axis and also the b-axis.
- the rotating build platform 210 may be a rigid and ring-shaped or annular structure (i.e. with an inner central hole) configured to rotate 360° around the center of rotation W.
- the rotating build platform 210 may be secured to an end mount of a motor 316 that is operable to selectively rotate the rotating build platform 210 around the center of rotation W such that the build platform 210 moves in a circular path.
- the motor 316 may be further secured to a stationary support structure 328.
- the motor may also be located elsewhere near the apparatus and mechanically connected with the build platform via a belt for translating motion of the motor to the build platform.
- outer collector 224 and inner collector 226 are positioned to remain adjacent to the outer surface 229 and the inner surface 231, respectively.
- the outer collectors 224 and inner collectors 226 temporarily trap powder along the outside of the outer wall 229 and the inner wall 231, respectively. While the powder is trapped by the collectors 224, 226, the energy source is used to melt the powder forming the object 230, such that its outer and inner surfaces 229, 231 are formed with powder is on either side.
- the collectors 100 may inhibit break down effects that are sometimes observed without powder on the external side of the built object 230.
- the excess powder on the exterior of the surfaces 229, 231 may then fall away to the outside of the part and be collected at a later time.
- a trailing vacuum could travel with head for immediate collection, and may be returned to the powder dispenser 512 itself.
- FIG. 3 shows an additive manufacturing apparatus 300 in accordance with another aspect of the present invention.
- the build unit 302 is attached to a gantry having "z" crossbeams 325Y, "x" crossbeam 325X and "y" crossbeam 325Y
- the build unit 302 can be rotated in the x-y plane as well as the z- plane as shown by the curved arrows in FIG. 3.
- the object being built 230 on the rotating build platform 210 has the powder bed (not shown) constrained by the outer collector 224 and an inner collector 226.
- FIG. 4 shows a side view of a manufacturing apparatus 300 including details of the build unit 302, which is pictured on the far side of the build platform.
- the mobile build unit 302 includes an irradiation beam directing mechanism 506, a gas-flow mechanism 532 with a gas inlet 534 and gas outlet 536 providing gas flow to a gas flow zone 538, and a powder recoating mechanism 504.
- Above the gas flow zone 538 there is an enclosure 540 that contains an inert environment 542.
- the powder recoating mechanism 504 which is mounted on a recoater plate 544, has a powder dispenser 512 that includes a back plate 546 and a front plate 548.
- the powder recoating mechanism 504 also includes at least one actuating element 552, at least one gate plate 516, a recoater blade 550, an actuator 518 and a recoater arm 508.
- the actuator 518 activates the actuating element 552 to pull the gate plate 516 away from the front plate 548, as shown in FIG. 4.
- FIG. 4 shows the build unit 302 with the gate plate 516 at an open position.
- the powder 515 in the powder dispenser 512 is deposited to make a fresh layer of powder 554, which is smoothed over a portion of the top surface (i.e. build or work surface) of the object 230 and within the powder cavity 113.
- the recoater blade 510 to make a substantially even powder layer 556 which is then irradiated by the irradiation beam 558 to a fused layer that is part of the printed object 230.
- the substantially even powder layer 556 may be irradiated at the same time as the build unit 302 is moving, which allows for a continuous operation of the build unit 302 and hence, a more time-efficient production of the printed or grown object 230.
- the selective powder recoating mechanism 504 may have a powder dispenser 512 with only a single compartment containing a raw material powder 515, though multiple compartments containing multiple different material powders are also possible.
- Multiple gate plates 516 may be utilized and independently controlled by the respective actuators 518.
- a selective recoating mechanism allows precise control of powder deposition using powder deposition device (e.g. a hopper) with independently controllable powder gate plates 516.
- the powder gate plates are controlled by at least one actuating element which may be, for instance, a bi-directional valve or a spring.
- Each powder gate can be opened and closed for particular periods of time, in particular patterns, to finely control the location and quantity of powder deposition.
- the powder dispenser 512 may contain dividing walls so that it contains multiple chambers, each chamber corresponding to a powder gate, and each chamber containing a particular powder material. The powder materials in the separate chambers may be the same, or they may be different.
- each powder gate can be made relatively small so that control over the powder deposition is as fine as possible.
- Each powder gate has a width that may be, for example, no greater than about 2 inches (in), or more preferably no greater than about 1 ⁇ 4 in.
- the smaller the powder gate the greater the powder deposition resolution, and there is no particular lower limit on the width of the powder gate.
- the sum of the widths of all powder gates may be smaller than the largest width of the object, and there is no particular upper limit on the width of the object relative to the sum of the widths of the power gates.
- a simple on/off powder gate mechanism according to an embodiment of the present invention is simpler and thus less prone to malfunctioning. It also advantageously permits the powder to come into contact with fewer parts, which reduces the possibility of contamination.
- each build unit 302 may have the associated collectors 100 attached thereto, along with associated positioning mechanisms 325.
- suitable powder materials can include metallic alloy, polymer, or ceramic powders.
- Exemplary metallic powder materials are stainless steel alloys, cobalt-chrome, aluminum alloys, titanium alloys, nickel based superalloys, and cobalt based superalloys.
- suitable alloys may include those that have been engineered to have good oxidation resistance, known
- “superalloys” which have acceptable strength at the elevated temperatures of operation in a gas turbine engine, e.g. Hastelloy, Inconel alloys (e.g., IN 738, IN 792, IN 939), Rene alloys (e.g., Rene N4, Rene N5, Rene 80, Rene 142, Rene 195), Haynes alloys, Mar M, CM 247, CM 247 LC, C263, 718, X-750, ECY 768, 282, X45, PWA 1483 and CMSX (e.g. CMSX-4) single crystal alloys.
- the manufactured objects of the present invention may be formed with one or more selected crystalline microstructures, such as directionally solidified (“DS") or single-crystal ("SX").
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Optics & Photonics (AREA)
- Powder Metallurgy (AREA)
Abstract
L'invention concerne un appareil de fabrication additive, ainsi que des procédés de formation d'un objet avec celui-ci. L'appareil de fabrication additive peut comprendre au moins une unité de construction; une plate-forme de construction (telle qu'une plateforme de construction rotative); et une paire de collecteurs positionnés sur l'appareil de telle sorte qu'un premier collecteur entre en contact avec une surface externe d'un objet lorsqu'il est formé sur la plateforme de construction et qu'un second collecteur entre en contact avec une surface interne de l'objet lorsqu'il est formé sur la plateforme de construction.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US16/761,717 US11986884B2 (en) | 2017-11-10 | 2018-11-02 | Apparatus and method for additive manufacturing |
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Application Number | Priority Date | Filing Date | Title |
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US201762584188P | 2017-11-10 | 2017-11-10 | |
US62/584,188 | 2017-11-10 |
Publications (1)
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WO2019094294A1 true WO2019094294A1 (fr) | 2019-05-16 |
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PCT/US2018/058927 WO2019094294A1 (fr) | 2017-11-10 | 2018-11-02 | Appareil et procédé de fabrication additive |
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EP3623139A1 (fr) * | 2018-09-14 | 2020-03-18 | Nederlandse Organisatie voor toegepast- natuurwetenschappelijk onderzoek TNO | Dispositif de recouvrement et procédé permettant d'appliquer une couche de matériau de construction capable de solidifier sur une surface de travail |
Citations (2)
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US20130197683A1 (en) * | 2010-04-15 | 2013-08-01 | Huazhong University Of Science And Technology | Method for manufacturing metal parts and molds and micro-roller used therefor |
DE102016111047B3 (de) * | 2016-06-16 | 2017-10-26 | Brandenburgische Technische Universität Cottbus-Senftenberg | Verfahren und Anlage zur kombiniert additiven und umformenden Fertigung |
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- 2018-11-02 US US16/761,717 patent/US11986884B2/en active Active
- 2018-11-02 WO PCT/US2018/058927 patent/WO2019094294A1/fr active Application Filing
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Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20130197683A1 (en) * | 2010-04-15 | 2013-08-01 | Huazhong University Of Science And Technology | Method for manufacturing metal parts and molds and micro-roller used therefor |
DE102016111047B3 (de) * | 2016-06-16 | 2017-10-26 | Brandenburgische Technische Universität Cottbus-Senftenberg | Verfahren und Anlage zur kombiniert additiven und umformenden Fertigung |
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US11986884B2 (en) | 2024-05-21 |
US20210370394A1 (en) | 2021-12-02 |
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